Methods and Apparatuses for Tucking Side Panels of Absorbent Articles

ABSTRACT

Aspects of the present disclosure relate to tucking opposing side panels into a chassis of a pant diaper. The apparatuses and methods may utilize one or more conveyors that advance the chassis along a machine direction. Each conveyor may have a vacuum zone that applies a vacuum force to hold the chassis. The chassis may be positioned between a first conveyor having a first vacuum zone and a second conveyor having a second vacuum zone. The conveyors may apply opposing vacuum forces to hold the first waist region apart from the second waist region while the chassis advances in the machine direction toward a tucking device. The tucking device may discharge air to push the side panels into the chassis and create longitudinal fold lines along edges of the absorbent core of the diaper.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.13/051,241, filed on Mar. 18, 2011, which claims the benefit of U.S.Provisional Application No. 61/322,338, filed on Apr. 9, 2010, both ofwhich are hereby incorporated by reference.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatuses formanufacturing absorbent articles, and more particularly, methods andapparatuses for tucking side panels of pant diapers.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. Webs of material andcomponent parts used to manufacture diapers may include: backsheets,topsheets, leg cuffs, waist caps, absorbent core components, frontand/or back ears, fastener components, and various types of elastic websand components such as leg elastics, barrier leg cuff elastics, stretchside panels, and waist elastics. Once the desired component parts areassembled, the advancing web(s) and component parts are subjected to afinal knife cut to separate the web(s) into discrete diapers or otherabsorbent articles.

After the final knife cut, absorbent articles may also undergo a foldingprocess prior to packaging. Pant diapers may also include additionalmanufacturing steps not used in the manufacture of conventional tapeddiapers. For example, pant diapers may include side panels that connectfront and rear waist regions with each other. Thus, after being foldedinto a U about a lateral centerline in the same or similar way asconventional diapers, the side panels on pant diapers may connect thefront and rear waist regions to form a waist opening and a pair of legopenings. In addition, the side panels may be laterally tucked insidethe pant diapers before packaging.

Some currently available side panel tucker processes advance the pantdiaper in a machine direction between upper and lower vacuum conveyors.In such configurations, the upper vacuum conveyor may apply an upwardvacuum force to the front waist region of the pant diaper while thelower vacuum conveyor may apply a downward vacuum force to the rearwaist region of the pant diaper. As such, the opposing vacuum forceshold the waist regions of the pant diaper apart from each other. Then,while the waist regions of the diaper are held apart by vacuum, arotating tucker blade may be used to push the side panels into theinterior of the diaper, creating longitudinal fold lines along thediaper. As such, some methods may rely on the location of the tuckerblades relative the diaper to control the location of the longitudinalfolds. Other methods may rely on the width of vacuum zones on theconveyors relative to the width of diaper to control the location of thelongitudinal folds. However, with such methods, the locations of thelongitudinal folds may be dictated in large part by the positions of thediapers relative to other equipment (e.g. conveyor, tuckers, etc.).Thus, the locations of the longitudinal folds in the diapers can beinconsistent due to varying positions of the diapers relative to suchequipment during manufacture.

SUMMARY OF THE INVENTION

Aspects of the present disclosure relate to apparatuses and methods fortucking first and second opposing side panels into a chassis of a pantdiaper.

In one form, a method may be configured for tucking first and secondopposing side panels into a chassis of a pant diaper, wherein thechassis includes an absorbent core having opposing longitudinal sideedges defining a lateral width, the chassis further including an innersurface and an outer surface, the chassis having longitudinally opposingfirst and second waist regions, longitudinally opposing first and secondwaist end edges disposed in the first and second waist regions adjacentto the respective waist end edges, a crotch region longitudinallyintermediate of the first and second waist regions, the first and secondside panels connecting the first waist region with the second waistregion to form a waist opening and a pair of leg openings. The methodmay include the steps of: positioning the chassis between a firstconveyor having a first vacuum zone and a second conveyor having asecond vacuum zone; applying a first vacuum force from the first vacuumzone to the first waist region and applying a second vacuum force fromthe second vacuum zone to the second waist region, wherein the firstvacuum zone and the second vacuum zone each define lateral widths thatare smaller than the lateral width of the absorbent core; holding thefirst waist region of the chassis apart from the second waist region ofthe chassis using opposing vacuum forces from the first and secondvacuum zones; advancing the chassis in a machine direction with thefirst and second conveyors; and discharging air against the first andsecond panels to push the first side panel and the second side panel adistance laterally inward toward each other; and creating longitudinalfolds in the chassis at the outer longitudinal edges of the absorbentcore.

In another form, a method may be configured for tucking first and secondopposing side panels into a chassis of a pant diaper, wherein thechassis includes an absorbent core having opposing longitudinal sideedges defining a lateral width, the chassis further including an innersurface and an outer surface, the chassis having longitudinally opposingfirst and second waist regions, longitudinally opposing first and secondwaist end edges disposed in the first and second waist regions adjacentto the respective waist end edges, a crotch region longitudinallyintermediate of the first and second waist regions, the first and secondside panels connecting the first waist region with the second waistregion to form a waist opening and a pair of leg openings. The methodmay include the steps of: positioning the chassis between a firstconveyor and a second conveyor; applying a holding force to the chassis;holding the chassis on the first conveyor using holding force; advancingthe chassis in a machine direction with the first conveyor; dischargingair against the first and second panels to push the first side panel andthe second side panel a distance laterally inward toward each other; andcreating longitudinal folds in the chassis at the outer longitudinaledges of the absorbent core.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view a pant diaper.

FIG. 2 is a partially cut away plan view of the pant diaper shown inFIG. 1.

FIG. 3 is a perspective view of the pant diaper of FIG. 1 with sidepanels tucked into the interior of a chassis.

FIG. 4 is a schematic side view of pant diapers traveling in a machinedirection along a side panel tucking apparatus.

FIG. 5 shows a cross-sectional view of the apparatus and a pant diaperof FIG. 4 taken along line 5-5.

FIG. 6 shows a cross-sectional view of the apparatus and a pant diaperof FIG. 4 taken along line 6-6.

FIG. 7 shows a cross-sectional view of a tucking apparatus utilizingrotating tucker blades with air discharged therefrom and the pant diaperof FIG. 6 taken along line 7-7.

FIG. 8 shows a cross-sectional view of a tucking apparatus utilizingconverging rails with air jets and the pant diaper of FIG. 6 taken alongline 7-7.

FIG. 9 shows a cross-sectional view of a tucking apparatus utilizingstationary nozzle members with air discharged intermittently.

FIG. 10 shows a cross-sectional view of the tucker apparatus of FIG. 9taken along line 10-10.

FIG. 11 shows a cross-sectional view of a tucking apparatus utilizingmoving nozzle members with air jets and pant diapers.

FIG. 12 shows a schematic side view of pant diapers traveling in amachine direction along a side panel tucking apparatus.

FIG. 12A is a top view of a conveyor including clamps in a closedposition.

FIG. 12B shows the clamps of FIG. 12A in an open position.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. Non-limitingexamples of absorbent articles include diapers, training pants, pull-onpant-type diapers, refastenable diapers or pant-type diapers,incontinence briefs and undergarments, diaper holders and liners,feminine hygiene garments such as panty liners, absorbent inserts, andthe like.

“Diaper” is used herein to refer to an absorbent article generally wornby infants and incontinent persons about the lower torso.

“Bi-fold” means the leading edge portion and the trailing edge portionof an article on a production line are brought together in aface-to-face configuration once the article is folded about a fold lineextending laterally across the article as the article moves in themachine direction of travel.

The term “disposable” is used herein to describe absorbent articleswhich generally are not intended to be laundered or otherwise restoredor reused as an absorbent article (e.g., they are intended to bediscarded after a single use and may also be configured to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner).

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer.

Aspects of the present disclosure involve methods and apparatuses formanufacturing articles, and more particularly, apparatuses and methodsfor tucking first and second laterally opposing side panels into achassis of a pant diaper. The pant diaper may include an absorbent corehaving opposing longitudinal side edges defining a lateral width. Asdiscussed in more detail below, the absorbent core and/or acquisitionsystem defines a location where the pant diaper naturally wants to foldas the side panels are tucked, because the lateral bending stiffness ofthe pant diaper along may be relatively high at the edge of theabsorbent core as compared to the side panels. The chassis may alsoinclude longitudinally opposing first and second waist regions, and acrotch region longitudinally intermediate of the first and second waistregions. The first and second side panels may connect the first waistregion with the second waist region to form a waist opening and a pairof leg openings. As discussed in more detail below, embodiments of theapparatuses and methods disclosed herein may utilize one or moreconveyors that advance the chassis along a machine direction. Eachconveyor may have a vacuum zone that applies a vacuum force to hold thechassis of the diaper. In some embodiments, the chassis is positionedbetween a first conveyor having a first vacuum zone and a secondconveyor having a second vacuum zone, wherein each vacuum zone defines alateral width that is less than the lateral width of the absorbent core.The conveyors may apply a first vacuum force from the first vacuum zoneto the first waist region and may apply a second vacuum force from thesecond vacuum zone to the second waist region. As such, the opposingvacuum forces hold the first waist region of the chassis apart from thesecond waist region of the chassis while the chassis advances in themachine direction toward a tucking device. While the first and secondwaist regions are held apart, a tucking device may push the side panelstoward each other. Because the lateral widths of the vacuum zones areless than the lateral width of the absorbent core, pushing the sidepanels toward each other creates longitudinal folds along lateral sideedges of the absorbent core. With the side panels tucked into thechassis, the front and rear waist regions may be pressed against eachother to maintain the side panels in the tucked position.

As discussed in more detail below, various different configurations ofside panel tuckers may be used to tuck the side panels into the chassis.The side panel tuckers according to the present disclosure utilize airdischarged against the side panels to push the side panels into thechassis. In some instances, using air, as opposed to controlledmechanical displacement, to push the side panels helps to reduce theneed to have a very precise and consistent relative position between theside panel tucker and the diaper. As such, the tucked width of thediaper may be independent of cross directional placement variations ofthe diaper relative to the conveyors and/or side panel tuckers.

The following provides a description of pant diapers and associatedcomponents to help provide additional context to the subsequentdiscussion of side panel tucking methods and apparatuses.

The terms “pant diaper” and “pant” (also referred to as “training pant,”“pre-closed diaper,” “diaper pant,” and “pull-on diaper”) refers hereinto disposable absorbent articles having a continuous perimeter waistopening and laterally opposing continuous perimeter leg openingsdesigned for infant or adult wearers. A pant can be configured with acontinuous or closed waist opening and at least one continuous, closed,leg opening as packaged, prior to the article being applied to thewearer. A pant can be preformed by various techniques including, but notlimited to, joining together portions of the article using anyrefastenable and/or permanent closure member (e.g., seams, heat bonds,pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.).A pant can be preformed anywhere along the circumference of the articlein the waist region (e.g., side fastened or seamed, front waist fastenedor seamed, rear waist fastened or seamed or combinations thereof).Example pants are disclosed in various configurations are disclosed inU.S. Pat. Nos. 5,246,433; 5,569,234; 6,120,487; 6,120,489; 4,940,464;5,092,861; 5,897,545; 5,957,908; 6,036,805; 6,113,717; and U.S. PatentPublication No. 2003/0233082.

For the purposes of a specific illustration, FIG. 1 shows one example ofa plan view of a pant diaper 100 including a chassis 102 and opposingfirst and second side panels 104, 106. FIG. 2 shows the pant diaper 100in a flat, unfolded condition, with the portion of the diaper that facesaway from a wearer oriented towards the viewer. A portion of the chassisstructure is cut-away in FIG. 2 to more clearly show the construction ofand various features that may be included in embodiments of the pantdiaper 100. FIG. 3 shows the pant diaper 100 of FIG. 1 with opposingside panels tucked into the chassis 102.

To provide a frame of reference for the present discussion, the chassis102 is shown with a longitudinal axis 108 and a lateral axis 110. Thechassis 102 is shown as having a first waist region 112, a second waistregion 114, and a crotch region 116 disposed intermediate the first andsecond waist regions. The periphery of the chassis 118 is defined by afirst longitudinal side edge 120, a second longitudinal side edge 122; afirst waist end edge 124 disposed in the first waist region 112; and asecond waist end edge 126 disposed in the second waist region 114. Asshown in FIG. 1, the first and second side panels 104, 106 connect thefirst waist region 112 with the second waist region 114 of the chassis102 to form a waist opening 128 and two leg openings 130.

As shown in FIGS. 1 and 2, the chassis includes an inner, body facingsurface 132, and an outer, garment facing surface 134. As shown in FIG.2, the chassis 102 may include a topsheet 138 forming a portion of thebody facing surface 132. The chassis 102 may also include a backsheet140 formed from a laminate including an outer covering layer and aninner layer. An absorbent core 142 may be disposed between a portion ofthe topsheet 138 and the backsheet 140. The chassis 102 may also includeleg elastics 144, such as shown in FIG. 2, and an elastic waist regionto enhance the fit around the legs and waist of the wearer. Example legelastic and leg cuff embodiments are disclosed in, for example, U.S.Pat. Nos. 4,695,278 and 4,795,454. It is to be appreciated that any oneor more of the regions of the chassis may be stretchable and may includevarious types of elastomeric materials and/or laminates. As such, thediaper may be configured to adapt to a specific wearer's anatomy uponapplication and to maintain contact with the wearer's anatomy duringwear.

As previously mentioned, the chassis 102 may include a backsheet 140,shown for example, in FIG. 2. The backsheet may also define the outersurface 134 of the chassis 102. In some embodiments, the backsheet maybe configured to prevent exudates absorbed and contained within thechassis from soiling articles that may contact the diaper, such asbedsheets and undergarments. Certain backsheet embodiments may be fluidpermeable, while other embodiments may be impervious to liquids (e.g.,urine) and include a thin plastic film. Some backsheet films may includethose manufactured by Tredegar Industries Inc. of Terre Haute, Ind. andsold under the trade names X15306, X10962, and X10964. Other backsheetmaterials may include breathable materials that permit vapors to escapefrom the diaper while still preventing exudates from passing through thebacksheet. Exemplary breathable materials may include materials such aswoven webs, nonwoven webs, composite materials such as film-coatednonwoven webs, monolithic films and microporous films. Examplebreathable composite materials are described in greater detail in PCTApplication No. WO 95/16746 and U.S. Pat. No. 5,865,823, both of whichare hereby incorporated by reference. Other breathable backsheetsincluding nonwoven webs and apertured formed films are described in U.S.Pat. Nos. 5,571,096 and 6,573,423, which are both hereby incorporated byreference.

The backsheet 140 may be formed by only one sheet (or layer) materialsuch as a breathable (or microporous or monolithic) film material or anon-breathable (or non-microporous) film material. In some embodiments,the backsheet may be formed by two (or more) sheet (or layer) materialswhich may include a non-breathable (or breathable) film material and anonwoven outer cover material. In some embodiments, the backsheet may beformed by a laminate of two sheet (or layer) materials joined together,for example, the backsheet may include a non-breathable film materialforming the inner layer of the backsheet and a nonwoven material formingthe outer layer which may be joined to the garment facing surface of thefilm material to provide a cloth-like and/or garment-like feel. Inaccordance with the discussion above, graphics may be printed on thefilm, the nonwoven, or the composite substrate to make printed componentmaterial, which may be converted into absorbent articles comprisingprinted backsheets.

As previously mentioned, the chassis 102 may include a topsheet 138,shown for example, in FIG. 2. The topsheet 138 may also define a portionof the inner surface 132 of the chassis 102. All or a portion of thetopsheet may be liquid pervious, permitting liquid to readily penetratethere through. As such, the topsheet may be manufactured from a widerange of materials, such as porous foams; reticulated foams; aperturednonwovens or plastic films; or woven or nonwoven webs of natural fibers(e.g., wood or cotton fibers), synthetic fibers (e.g., polyester orpolypropylene fibers), or a combination of natural and synthetic fibers.One example of a topsheet including a web of staple length polypropylenefibers is manufactured by Veratec, Inc., a Division of InternationalPaper Company, of Walpole, Mass. under the designation P-8. Examples offormed film topsheets are described in U.S. Pat. Nos. 3,929,135;4,324,246; 4,342,314; 4,463,045; and 5,006,394, all of which are herebyincorporated by reference herein. Other topsheets may be made inaccordance with U.S. Patent Nos. 4,609,518 and 4,629,643, both of whichare hereby incorporated by reference.

In some embodiments, the topsheet is made of a hydrophobic material oris treated to be hydrophobic in order to isolate the wearer's skin fromliquids contained in the absorbent core. If the topsheet is made of ahydrophobic material, at least the upper surface of the topsheet may betreated to be hydrophilic so that liquids will transfer through thetopsheet more rapidly. The topsheet can be rendered hydrophilic bytreating it with a surfactant or by incorporating a surfactant into thetopsheet. A more detailed discussion of such a treatment andhydrophilicity is contained in U.S. Pat. Nos. 4,988,344 and 4,988,345,both of which are hereby incorporated by reference. A more detaileddiscussion of some methods for incorporating surfactant in the topsheetcan be found in U.S. Statutory Invention Registration No. H1670, whichwas published on Jul. 1, 1997, in the names of Aziz et al., all of whichare hereby incorporated by reference. In some embodiments, the topsheet138 may include an apertured web or film that is hydrophobic. This maybe accomplished eliminating the hydrophilizing treatment step from theproduction process and/or applying a hydrophobic treatment to thetopsheet, such as a polytetrafluoroethylene compound like SCOTCHGUARD ora hydrophobic lotion composition, as described below. A more detaileddiscussion of various apertured topsheets can be found in U.S. Pat. Nos.5,342,338; 5,941,864; 6,010,491; and 6,414,215, all of which are herebyincorporated by referenced.

As previously mentioned, the chassis 102 may also include an absorbentcore 142. As shown for example in FIG. 2, the absorbent core 142 mayinclude a first longitudinal side edge 146 laterally separated from asecond longitudinal side edge 148, and a first end edge 150longitudinally separated from a second end edge 152. The absorbent coremay also include components such as an acquisition layer and absorbentmaterial that is generally compressible, conformable, non-irritating tothe wearer's skin and capable of absorbing and retaining liquids such asurine and other body exudates. The absorbent core can also bemanufactured in a wide variety of sizes and shapes (e.g., rectangular,hourglass, T-shaped, asymmetric, etc.). The absorbent core may alsoinclude a wide variety of liquid-absorbent materials commonly used indisposable diapers and other absorbent articles. In one example, theabsorbent core includes comminuted wood pulp, which is generallyreferred to as airfelt. Examples of other absorbent materials includecreped cellulose wadding; meltblown polymers, including conform;chemically stiffened, modified or cross-linked cellulosic fibers;tissue, including tissue wraps and tissue laminates; absorbent foams;absorbent sponges; superabsorbent polymers; absorbent gelling materials;or any other known absorbent material or combinations of materials.

It is to be appreciated that the configuration and construction of theabsorbent core may be varied (e.g., the absorbent core(s) or otherabsorbent structure(s) may have varying caliper zones, a hydrophilicgradient, a superabsorbent gradient, or lower average density and loweraverage basis weight acquisition zones; or may comprise one or morelayers or structures). Exemplary absorbent structures are described inU.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735; 4,888,231; 5,137,537;5,147,345; 5,342,338; 5,260,345; 5,387,207; and 5,650,222, all of whichare hereby incorporated by reference.

The absorbent core may also have a multiple layered construction. A moredetailed discussion of various types of multi-layered absorbent corescan be found in U.S. Pat. Publication Nos. 2004/0162536A1 and2004/0167486A1; U.S. Pat. Nos. 5,669,894; 6,441,266; 5,562,646; EuropeanPat. No. EP0565606B1; PCT Publication No. WO 2006/015141, which are allhereby incorporated by reference. In some embodiments, the pant diaperincludes an absorbent core that is stretchable. In such a configuration,the absorbent core may be adapted to extend along with other materialsof the chassis in longitudinal and/or lateral directions. The absorbentcore can also be connected with the other components of the chassisvarious ways. For example, the diaper may include a “floating core”configuration or a “bucket” configuration wherein the diaper includes ananchoring system that can be configured to counteract the forces tendingto move the article on the wearer. Such an anchoring system can also beconfigured to anchor itself to a body of a wearer by contacting variousparts of the body. In this way, the anchoring system can balance thecollected moving forces with holding forces obtained from the anchoring.By balancing the collected moving forces with the obtained holdingforces, the anchoring system can at least assist in holding thedisposable wearable absorbent article in place on a wearer.

Embodiments of the pant diaper may also include pockets for receivingand containing waste, spacers which provide voids for waste, barriersfor limiting the movement of waste in the article, compartments or voidswhich accept and contain waste materials deposited in the diaper, andthe like, or any combinations thereof. Examples of pockets and spacersfor use in absorbent products are described in U.S. Pat. Nos. 5,514,121;5,171,236; 5,306,266; 5,397,318; 5,540,671; and PCT Application WO93/25172; which are all hereby incorporated by reference. Examples ofcompartments or voids are disclosed in U.S. Pat. Nos. 4,968,312;4,990,147; 5,062,840; 6,482,191; and 5,269,755, which are all herebyincorporated by reference. Examples transverse barriers are described inU.S. Pat. Nos. 5,554,142 and 5,653,703; and PCT Patent Publication WO94/14395, which are all hereby incorporated by reference. In addition toor in place of the voids, pockets and barriers, described above,embodiments of the absorbent article may also include a waste managementelement capable of effectively and efficiently accepting, storing and/orimmobilizing viscous fluid bodily waste, such as runny feces, such asdescribed in U.S. Pat. No. 6,010,491, which is hereby incorporated byreference.

As previously mentioned with reference to FIG. 1, embodiments of thepant diaper may include first and second side panels 104, 106 thatconnect the first waist region 112 with the second waist region 114 ofthe chassis 102 to form the waist opening 128 and two leg openings 130.As shown in FIGS. 1 and 2, the first side panel 104 includes a first earpanel 104 a connected with a second ear panel 104 b, and the second sidepanel 106 includes a first ear panel 106 a connected with a second earpanel 106 b. The first ear panels 104 a, 106 a each include proximalregions connected with the first waist region 112 of the chassis 102.And second first ear panels 104 b, 106 b each include proximal regionsconnected with the second waist region 114 of the chassis 102. Distalregions of the first ear panel 104 a and the second ear panel 104 b maybe connected or fastened to each other to form the first side panel 104,and distal regions of the first ear panel 106 a and the second ear panel106 b may be connected or fastened to each other to form the second sidepanel 106. Although the side panels shown in FIGS. 1 and 2 are formed byconnecting ear panels together, it is to be appreciated that the sidepanels may be of a single unitary piece construction. It should beappreciated that the side panels may also be formed as continuousextensions of one or both the first and second waist regions of thechassis. It is also to be appreciated that embodiments of the pantdiaper that may be used with the methods and apparatuses herein mayinclude various different types and configurations of side panels thanthose shown and described herein. Examples of various types of sidepanels are disclosed in U.S. Pat. Nos. 5,246,433; 5,569,234; 6,120,487;6,120,489; 4,940,464; 5,092,861; 5,897,545; 5,957,908; 6,036,805;6,113,717; and U.S. Patent Publication No. 2003/0233082 all of which areincorporated herein by reference.

It is to be appreciated that the proximal regions of the ear panels maybe connected with the chassis in various ways, and the distal regions ofthe ear panels may be connected with each other in various ways. Forexample, the proximal regions and/or distal regions of the side panelsmay be permanently bonded, releasably connected, and/or refastenablyconnected with the chassis and/or each other, with for example,adhesives, cohesives, thermal bonding, ultrasonic bonding, mechanicalbonding and mechanical fastening, e.g. hook and loop type fasteners. Forexample, one or more fastener elements may be located on the side panelsand may be adapted to refastenably connect with one or morecorresponding fastening elements located in the first or second waistregions or alternatively the fastener elements may be adapted torefastenably connect with one or more components of the absorbentarticle including the side panels. The pant diapers can also includeother features such as elastically extensible side panels that may eachinclude one or more pieces of material.

Depending on the particular configuration, it is to be appreciated thatvarious types of fastening elements may be used with the pant diaper. Inone example, the fastening elements include hook & loop fasteners, suchas those available from 3M or Velcro Industries. In other examples, thefastening elements include adhesives and/or tap tabs, while others areconfigured as a macrofastener or hook (e.g., a MACRO or “button-like”fastener). Some exemplary fastening elements and systems are disclosedin U.S. Pat. Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527;5,151,092; and 5,221,274, which are all hereby incorporated byreference. Additional examples of fasteners and/or fastening elementsare discussed in U.S. Pat. Nos. 6,482,191; 6,251,097; and 6,432,098,which are all hereby incorporated by reference. Other fastening systemsare described in more detail in U.S. Pat. Nos. 5,595,567; 5,624,427;5,735,840; and 5,928,212, which are all hereby incorporated byreference. The fastening system may also provide a means for holding thearticle in a disposal configuration as disclosed in U.S. Pat. No.4,963,140, which is hereby incorporated by reference.

As previously mentioned, the apparatuses and methods according to thepresent disclosure may be utilized to tuck first and second opposingside panels 104, 106 into the chassis 102 of the pant diaper 100. FIG. 1shows a pant diaper 100 with the first and second side panels 104, 106in an untucked configuration, and FIG. 3 shows the pant diaper 100 withopposing side panels 104, 106 tucked into the chassis 102. As shown inFIG. 3, portions of each side panel 104, 106 inserted into the chassis102 of the pant diaper 100 such that portions of the side panels aredisposed between the interior surface 132 of the first waist region 112and the second waist region 114. In addition, the insertion of the sidepanels 104, 106 into the chassis 102 defines first longitudinal foldlines 150 along the first waist region 112 and second longitudinal foldlines 152 along the second waist region 114.

FIG. 4 shows an embodiment of an apparatus 200 for tucking side panels104, 106 into the chassis 102. The apparatus 200 can include a firstconveyance 202, a second conveyance 204, and a third conveyance 205.Each conveyance 202, 204, 205 may be in the form of a conveyor andinclude a movable surface 206 that may be in the form of a belt 208wrapped around rollers 210 and configured in an endless loop. One ormore of the belts 208 may also be configured as a movable foraminousvacuum conveyor belt that exerts vacuum forces on the chassis 102 toreceive, hold, and/or transfer the pant diaper 100. It is to beappreciated that each conveyance may include more than one conveyor,such as for example, multiple conveyors arranged in series along themachine direction and/or arranged in parallel along the cross direction.In addition, one or more of the conveyances can be configured as arotating drum or vacuum drum. As discussed in more detail below, theconveyances 202, 204, 205 advance pant diapers 100 in a machinedirection, MD, through a tucking zone 212, represented generally by adashed line box in FIG. 4, wherein a side panel tucker pushes the sidepanels 104 and 106 into the chassis 102.

As shown in FIG. 4, pant diapers 100 are received between the firstconveyance 202 and the second conveyance 204. It is to be appreciatedthat the pant diapers 100 may be subjected to various methods andapparatuses of assembly and construction before being received byconveyances 202, 204. Examples of such upstream processes andapparatuses are disclosed in U.S. Pat. Nos. 5,779,831; 6,036,805:6,113,717; 6,497,032; 7,175,584; 7,322,925; and 7,335,150 and U.S.Patent Publication Nos. 2008/0083489A1; 2009/0098995A1; and2009/0094941A1 all of which are incorporated herein by reference. Aspreviously mentioned, the first conveyance 202 and second conveyance 204may exert vacuum forces on the chassis 102 of the pant diaper 100 as thefirst and second conveyances 202, 204 advance the pant diaper in themachine direction, MD. For example, as shown in FIG. 4, the belts 206 ofthe first conveyance 202 and the second conveyance 204 exert opposingvacuum forces on the outer surfaces 134 of the first waist region 112and the second waist region 114. The belts 206 of the first conveyance202 and the second conveyance 204 may also diverge from each other alongat least a portion of the machine direction length of the conveyance204. Thus, as the chassis 102 advances along the machine direction, theopposing vacuum forces exerted on the first and second waist regions ofthe chassis pull and hold the inner surfaces 132 of the first and secondwaist regions 112, 114 apart from each other.

FIG. 5 shows a cross-sectional view of the pant diaper 100 and first andsecond conveyances 202, 204 of FIG. 4 taken along line 5-5. As shown inFIG. 5, the belt 206 of the first vacuum conveyance 202 includes avacuum zone 214 that exerts a downward vacuum force on the outer surface134 of the first waist region 112 of the chassis 102. And the belt 206of the second vacuum conveyance 204 includes a vacuum zone 214 thatexerts an upward vacuum force on the outer surface 134 of the secondwaist region 114 of the chassis 102. As such, the opposing forcesexerted by the vacuum zones 214 on chassis 102 hold the inner surfaces132 of the first and second waist regions 112 and 114 apart. Inaddition, the side panels 104 and 106 are shown in FIG. 5 in arelatively elongated and untucked configuration prior to the side paneltucker.

As shown in FIG. 5, the vacuum zones 214 of the first and secondconveyances 202, 204 each define a lateral or cross directional, CD,width ZW that are less than the lateral width CW defined by the opposinglongitudinal edges 146 and 148 of the absorbent core 142. As such, thelateral or cross directional, CD, width ZW of the vacuum zones 214 mayalso be less than the lateral width defined by the opposing longitudinaledges 120 and 122 of the chassis 102. It is to be appreciated that thevacuum zones may be configured with different lateral widths and maydefine lateral widths that are larger or smaller than what is depicted.For example, some embodiments may include vacuum zones having lateralwidths that are equal to or substantially equal to the lateral widths ofthe absorbent core and/or chassis. In addition, the conveyances may alsobe configured with more than one vacuum zone along the cross directionCD and/or machine direction MD.

As previously mentioned with reference to FIG. 4, as the pant diaper 100advances in the machine direction through the tucking zone 212, a sidepanel tucker 216 pushes the side panels 104 and 106 into the chassis102, such as shown for example in FIG. 6. As the side panels 104 and 106are pushed into the chassis 102, the inner surfaces 132 of the firstwaist region 112 and the second waist region 114 may move toward eachother. Tucking the side panels 104 and 106 into the chassis 102 createslongitudinal fold lines 150 and 152 in the chassis 102. In theconfiguration shown in FIG. 6, the longitudinal fold lines 150 and 152also coincide with and are defined by the longitudinal side edges 146and 148 of the absorbent core 142. It is to be appreciated that thelongitudinal fold lines 150 and 152 may be created in various differentlocations depending on the absorbent article configuration and/ortucking method. It should be appreciated that in some configurations,one or both the opposing vacuum forces exerted by the first and secondconveyance 202 and 204 may be removed from the chassis while the sidepanel tucker pushes the side panels 104 and 106 into the chassis 102.Such a configuration is described for example in U.S. Provisional PatentApplication identified by Attorney Docket No. 11682P, entitled “Methodsand Apparatuses for Tucking Side Panels of Absorbent Articles,” andfiled on Apr. 9, 2010.

It is to be appreciated that side panel tuckers 216 may be configured invarious different ways. For example, as shown in FIG. 7, the side paneltuckers 216 are configured as rotating blades 218, wherein air 219 isdischarged from the blades 218. As the pant diaper 100 advances in themachine direction past the side panel tuckers 216, air 219 dischargedfrom the rotating blade or blades 218 impinges on each of the sidepanels 104 and 106 and pushes the side panels into the chassis 102. Inanother embodiment, shown in FIG. 8, the side panel tuckers 216 areconfigured as rails 220, wherein air 219 is discharged from the rails220. As the pant diaper 100 advances in the machine direction past theside panel tuckers 216, air 219 discharged in the cross direction, CD,from the rails 220 impinges on each of the side panels 104 and 106 andpushes the side panels into the chassis 102. As shown in FIG. 8, therails 220 also converge toward each other in the cross direction, CD.

In yet other embodiments, the side panel tuckers may be configured tointermittently discharge air to push the side panels into the chassis.For example, FIG. 9 shows side panel tuckers 216 that includes a firstnozzle 300 that discharges air 219 toward the first side panel 104, anda second nozzle 302 that discharges air 219 toward the second sidepanel. With particular reference to FIGS. 9 and 10, the conveyor belt208 includes sets 305 of apertures 306 spaced laterally outside the sidepanels 104, 106. The sets 305 of apertures 306 are also spaced from eachother along the longitudinal length, or machine direction, of theconveyor belt 208 such that the apertures are aligned along thelongitudinal lengths of the side panels 104, 106. As shown in FIG. 10,pressurized air 304 travels upward through apertures 306 in the conveyorbelt 208. As the conveyor belt 208 travels in the machine direction MDunder the nozzles 300, 302, the pressurized air 304 is channeled throughthe nozzles 300, 302 and the air 219 is discharge from the nozzles 300,302 toward the side panels 104, 106 while side panels move past thenozzles.

Air 219 discharged from the nozzles 300, 302 push the side panels 104,106 into the chassis 102. As the conveyor belt apertures 306 advancepast the nozzles 300, 302, air is no longer discharged from the nozzles,until the next group 305 of apertures 306 passes under the nozzles 300,302. Although each group 305 is shown to include 3 apertures 306, it isto be appreciated that a group 305 may include more or less than 3apertures 306. Thus, air is intermittently discharge from the nozzles300, 302 as the apertures 306 in the conveyor 208 pass under thenozzles. It should also be appreciated that the side panel tuckers maybe configured as one of the aforementioned devices that alsointermittently discharges air to push the side panels into the chassisas the side panels advance past the side panel tuckers.

In yet other embodiments, the side panel tucker may be configured tomove along with the side panels in the machine direction whiledischarging air to push the side panels into the chassis. For example,FIG. 11 shows side panel tuckers 216 that include nozzles 400 connectedwith a conveyor configured as an endless belt 402. The belt 402 carriesthe nozzles 400 in the machine direction along side the side panels 104,106. The nozzles may be configured to discharge air 219 toward the sidepanels 104, 106 to push the side panels into the chassis 102. Thenozzles 400 may also be configured to discharge air 219 only when thenozzles are in relatively close proximity to the side panels 104, 106.In addition, as shown in FIG. 11, the belt 402 may also be configured tomove the nozzles 400 in the cross direction and closer to the sidepanels 104, 106 as the nozzles advance with the side panels 104, 106 inthe machine direction.

Referring back to FIG. 4, once the side panels 104 and 106 are pushedinto the chassis 102, the pant diaper 100 may continue to advance on thefirst conveyance 202 in the machine direction. The waist regions 112,114 of the pant diaper 100 may also be further compressed together tohelp hold the side panels 104 and 106 in the tucked position. Forexample, as shown in FIG. 4, after the tucking zone 212, the pantdiapers 100 advance between the first conveyance 202 and the thirdconveyance 205. The belts 206 of the first conveyance 202 and the thirdconveyance 205 may be spaced closer together than the first conveyance202 and second conveyance 204, or the belts 206 may converge toward eachother as the pant diaper 100 travels in the machine direction.

In still other embodiments, the side panel tucker may be configured withconveyors that do not utilized vacuum forces to hold the first andsecond waist regions apart while the side panels are tucked into thechassis. For example, FIG. 12 shows pant diapers 100 received from afolding apparatus 500, such as described for example in U.S. Pat. Nos.5,779,831. It is to be appreciated that the folding apparatus 500 ofFIG. 12 could also be configured as apparatuses disclosed in U.S. Pat.Nos. 6,036,805; 6,113,717; 6,497,032; 7,175,584; 7,322,925; and7,335,150 and U.S. Patent Publication Nos. 2008/0083489A1;2009/0098995A1; and 2009/0094941A1. As shown in FIG. 12, pant diapers100 on the folding apparatus 500 are received between a first conveyor502 and a second conveyor 504, each in the form of belt conveyors.Instead of utilizing vacuums to hold the diapers 100, the first conveyorincludes clamps 506 that engage diapers and hold the diapers to thefirst conveyor 502. The diapers 100 pass through a tucking zone 508,represented generally by a dashed line oval in FIG. 12, wherein a sidepanel tucker, such as the embodiments described above, pushes the sidepanels into the chassis 102. After the tucking zone, the clamps 506 maybe configured to release the diaper 100. It is to be appreciated thatvarious configurations of clamps 506 may be used. FIGS. 12A and 12B showan example configuration of conveyor 502 including clamps 506. FIG. 12Ashows the clamps 506 in a closed position, and FIG. 12B shows the clampsin an open position. As shown in FIGS. 12A and 12B, the clamps 506 mayrotate inwardly toward each other to a closed position along the belt ofthe conveyor 502 when engaging and holding a diaper. The clamps 506 mayalso rotate outwardly away from each other to an open position along thebelt of the conveyor 502 when releasing a diaper.

It is to be appreciated that although the conveyors 502, 504 of FIG. 12do not use vacuum forces to hold the chassis, one or both the conveyorsmay be configured with vacuum zones as described above. It is to beappreciated that various configurations of side panel tuckers could beutilized with the conveyor clamping arrangement shown in FIG. 12, suchas described above and in U.S. Provisional Patent Application identifiedby Attorney Docket No. 11682P, entitled “Methods and Apparatuses forTucking Side Panels of Absorbent Articles,” and filed on Apr. 9, 2010,as well as U.S. Pat. Nos. 6,723,035 and 6,776,316.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for tucking first and second opposingside panels into a chassis of a pant diaper, the chassis including anabsorbent core having opposing longitudinal side edges defining alateral width, the chassis further including an inner surface and anouter surface, the chassis having longitudinally opposing first andsecond waist regions, longitudinally opposing first and second waist endedges disposed in the first and second waist regions adjacent to therespective waist end edges, a crotch region longitudinally intermediateof the first and second waist regions, the first and second side panelsconnecting the first waist region with the second waist region to form awaist opening and a pair of leg openings, the method comprising thesteps of: positioning the chassis between a first conveyor having afirst vacuum zone and a second conveyor having a second vacuum zone;applying a first vacuum force from the first vacuum zone to the firstwaist region and applying a second vacuum force from the second vacuumzone to the second waist region, wherein the first vacuum zone and thesecond vacuum zone each define lateral widths that are smaller than thelateral width of the absorbent core; holding the first waist region ofthe chassis apart from the second waist region of the chassis usingopposing vacuum forces from the first and second vacuum zones; advancingthe chassis in a machine direction with the first and second conveyors;and discharging air against the first and second panels to push thefirst side panel and the second side panel a distance laterally inwardtoward each other; and creating longitudinal folds in the chassis at theouter longitudinal edges of the absorbent core.
 2. The method of claim1, further comprising the step of moving the first side panel in themachine direction along a first stationary rail and moving the secondside panel in the machine direction along a second stationary rail. 3.The method of claim 2, wherein the step of discharging air furthercomprises discharging air from the first stationary rail against thefirst side panel and from second stationary rail against the second sidepanel.
 4. The method of claim 1, further comprising the step of movingthe first side panel in the machine direction along a first rotatingtucker blade and moving the second side panel in the machine directionalong a second rotating tucker blade.
 5. The method of claim 1, furthercomprising the step of removing the first vacuum force from the firstwaist region and removing the second vacuum force from the second waistregion and creating longitudinal folds in the chassis while the firstvacuum force and the second vacuum force are removed from the first andsecond waist regions.
 6. The method of claim 1, further comprising thestep of moving the inner surface of the chassis in the first waistregion and the second waist region toward each other while creatinglongitudinal folds in the chassis.
 7. The method of claim 1, wherein thefirst conveyor comprises an endless belt.
 8. The method of claim 1,wherein the first and second side panels refastenably connect the firstwaist region with the second waist region.
 9. A method for tucking firstand second opposing side panels into a chassis of a pant diaper, thechassis including an absorbent core having opposing longitudinal sideedges defining a lateral width, the chassis further including an innersurface and an outer surface, the chassis having longitudinally opposingfirst and second waist regions, longitudinally opposing first and secondwaist end edges disposed in the first and second waist regions adjacentto the respective waist end edges, a crotch region longitudinallyintermediate of the first and second waist regions, the first and secondside panels connecting the first waist region with the second waistregion to form a waist opening and a pair of leg openings, the methodcomprising the steps of: positioning the chassis between a firstconveyor and a second conveyor; applying a holding force to the chassis;holding the chassis on the first conveyor using holding force; advancingthe chassis in a machine direction with the first conveyor; dischargingair against the first and second panels to push the first side panel andthe second side panel a distance laterally inward toward each other; andcreating longitudinal folds in the chassis at the outer longitudinaledges of the absorbent core.
 10. The method of claim 9, wherein the stepof applying a holding force to the chassis further comprises applying avacuum force from the vacuum zone to the first waist region of thechassis, wherein the vacuum zone defines a lateral width that is smallerthan the lateral width of the absorbent core.
 11. The method of claim 9,wherein first conveyor comprises clamp members, and wherein the step ofapplying a holding force to the chassis further comprises engaging theclamp members with the chassis.
 12. The method of claim 9, furthercomprising the step of moving the first side panel in the machinedirection along a first stationary rail and moving the second side panelin the machine direction along a second stationary rail.
 13. The methodof claim 9, further comprising the step of moving the inner surface ofthe chassis in the first waist region and the second waist region towardeach other while discharging air.